Onan Performer Series User manual

Performer Series
Printed in U.S.A.
965-0167
2-96

oroughly read the OPERATOR’S MANUAL before
c aerating the engine. Safe operation and top perfor-
~iance can be obtained only with proper operation
and maintenance.
_ - e -allowing symbols in this Manual alert you to potential
- a;="ds to the operator, service person and equipment.
r
DANGER
_ Alerts you to an immediate hazard
which will result in severe personal injury or death.
AV.'ARNiNGl Alerts you to a hazard or unsafe
practice which can result in severe persona! injury or
t
death.
A caution! Alerts you to a hazard or unsafe
practice which can result in personal injury or equip¬
ment damage.
E sctricity, fuel, exhaust, moving parts and batteries
: -esent hazards which can result in severe personal inju-
'/ or death.
*
GENERAL PRECAUTIONS
8 i AWARNINGI This engine is not designed or in¬
tended for use in aircraft. Such use can lead to
engine failure, severe personal injury or death.
FUEL IS FLAMMABLE AND EXPLOSIVE
• Keep flames, cigarettes, sparks, pilot lights, electri¬
cal arc-producing equipment and switches and all
other sources of ignition well away from areas where
fuel fumes are present and areas sharing ventila¬
tion.
while the engine is running.
Fuel lines must be copper cr steel tubing or piping,
adequately secured ar-d free of leaks.
Use approved
the engine. Do
connector—vibration \vi!
x!D;3 ruel hose for connections at
not use copper tubing as a flexible
ause it to work-harden
and break. Use non-conductive hose if the fuel line
ould become a oath for cranking current.
A
La
® The fuel line must have a manual shutoff valve un¬
less the highest fuel levei in the supply tank is lower
than the connection at the engine.
• Keep ABC fire extinguishers handy.
• Make sure all fasteners are secure and torqued
properly.
• Keep the engine and its compartment clean. Excess
oil and oily rags can catch fire. Dirt and gear stowed
in the compartment can restrict cooling air.
• Before working on the engine, disconnect the nega¬
tive (-) battery cable at the battery to prevent start¬
ing.
• Use caution when making adjustments while the en¬
gine is running—hot, moving or electrically live parts
can cause severe personal injury or death.
• Used engine oil has been identified by some state
and federal agencies as causing cancer or
reproductive toxicity. Do not ingest, inhale, c
contact used oil or its vapors.
• Benzene and lead in some gasolines have been
Identified by some state and federal agencies as
causing cancer or reproductive toxicity. Do not to
Ingest, inhale or contact gasoline or its vapors.
• Do not work on the engine when mentally or physi¬
cally fatigued or after consuming alcohol or drugs.
• Carefully follow all applicable local, state and federal
codes.
ENGINE EXHAUST IS DEADLY!
» Learn the symptoms of carbon monoxide poisoning
in this Manual.
» Inspect the exhaust system every time the engine is
started and after every eight hours of operation. If
the exhaust noise changes, shut down the engine
immediately and have it inspected.
9 DO NOT use engine cooling air to heat a room.
» Make sure there : s ample fresh air when operating
the enain.e in a confined area.
MOVING PARTS CAN CAUSE SEVERE
INJURY OR DEATH
» Dc not .vear ocse coming or jewelry near moving
^ i'
* _ #
shafts, fans, beits and pulleys.
■ 4
. \ w w
s s\vs 1 / from moving parts.
©
w w
over fans, beits, puileys, etc
BATTERY GAS IS EXPLO
«•
. /EAR SAFETY GLASSES and DO NO I SMOKE
« v . *;. w 'w
-[ V . M : w-O.
© When
cables,
cable fi
Jifiwvl L . iUw!) iU
or reconnecting battery
hnect the negative (-) battery
t and reconnect it last to reduce arcing.
!\‘,'ouc , /N i!

TITLE r»
Table of Contents
PAGE
SAFETY PRECAUTIONS .
INTRODUCTION ..
About This Manual.
Model Identification .
Fuel Recommendations ....
Engine Oil Recommendations
Starting Batteries .
Exhaust System .
OPERATION.
Pre-Start Checks . 6
Starting.. g
Engine Break-In ...... . 7
Operation In Dusty Conditions. 7
Operation In Hot Weather... 7
Operation in Cold Weather. 7
Out-of-Service Protection..... g
Returning The Engine To Service . g
PERIODIC MAINTENANCE . 9
Daily (8 Hour) Maintenance.... in
Engine Oil And Filter Change. . 1 1
Air Cleaner Maintenance . 12
Cooling System Maintenance . 13
Fuel Filter Replacement . 13
Spark Plug Replacement . 13
ADJUSTMENTS . 1 4
Carburetor Adjustments . 14
Reconnecting The Choke Cable . 14
Engine Speed Adjustments .. 15
TROUBLESHOOTING. 16
SPECIFICATIONS. 17
INFORMATION FOR CALIFORNIA ENGINE USERS . 18
Inside Front Cover
. 2
... 2
... 2
. 4
. 4
. 5
. 5
The engine exhaust from this product
contains chemicals known
State
California
cause cancer, birth
defects
other reproductive harm

Introduction
ABOUT THIS MANUAL
This manual covers the operation and maintenance
of the horizontal-shaft Performer Series of engines.
Each operator of the power equipment should study
this engine manual carefully and observe all of its
instructions and precautions. Proper use and peri¬
odic maintenance are responsibilities of the opera¬
tors) and are essential for top performance.
MODEL IDENTIFICATION
Whenever contacting an Onan dealer or distributor
for information, parts or service, always provide the
model number and the serial number marked on the
nameplate of the engine. (The serial number is in
the row marked “S/N”, just below the model num¬
ber.) Figure 1 illustrates atypical engine nameplate
and Figure 2 the location of the nameplate on the
engine.
Genuine Onan replacement parts obtained from an
Onan dealer or distributor are recommended.
□ [warning I Improper service or parts replace¬
ment can lead to severe personal injury or death
and to damage to equipment and property. Ser¬
vice personnel must be qualified to perform
electrical and mechanical service.
IMPORTANT ENGINE INFORMATION
ONAN CORPORATION
1400 73rd Ave. NE
Minneapolis, MN 5543
made in u.s.
Engine Model:
P224G-S/1264F
S/N: L951234567
REFER TO OPERATOR’S MANUAL FOR
MAINTENANCE SPECIFICATIONS
AND ADJUSTMENTS.
THIS ENGINE MEETS 1995 -1998
CALIFORNIA EMIS
REGULATIONS
FOR ULGE ENGINES
SN5980U1G2RA
UNLE A D E D GASOLINE ONLY
FIGURE 1. TYPICAL ENGINE NAMEPLATE
IAwarning] Unauthorized modifications or re¬
placement of fuel, exhaust, air intake or speed
control system components that affect engine
emissions are prohibited by law in the State of
California.
IAwarning! LPG (liquified petroleum gas) is
flammable and explosive and can cause as¬
phyxiation. NFPA 58 , Section 1.6 requires all
persons handling LPG to be trained in proper
handling and operating procedures.

FIGURE 2. TYPICAL ENGINE CONFIGURATION

FUEL RECOMMENDATIONS
[Awarning I Gasoline and LPG are highly flam¬
mable fuels andean cause severe personal inju¬
ry or death. Do not smoke if you smell gas or
gasoline or are near fuel tanks or fuel-burning
equipment or are in an area sharing ventilation
with such equipment. Keep flames, sparks, pilot
lights, electrical arcs and arc-producing equip¬
ment and all other sources of ignition well away.
Keep a type ABC fire extinguisher nearby.
Gasoline Models
Use clean, fresh unleaded gasoline having a mini¬
mum octane rating (Anti-Knock index) of 87 .
During some times of the year only mandated “oxy¬
genated” gasolines may be available. These are ac¬
ceptable for use, but not preferable. Leaded gaso¬
line may be used but will result in the extra mainte¬
nance required for removing combustion chamber
and spark plug deposits. Do not use gasoline or
gasoline additives (de-icers) containing methanol
because methanol can be corrosive to fuel system
components.
percent propane. Commercial LPG may contain
more than 2.5 percent butane which can result in
poor fuel vaporization and poor engine starting in
low ambient temperatures (below 32 ° F ( 0 ° C).
Natural Gas Models
Use commercially available natural gas fuel.
ENGINE OIL RECOMMENDATIONS
Use premium quality motor oil. Look for the API
(American Petroleum Institute) classification and
use Class SG or SH oil (also SG/CD, SG/CE, SH/
CD or SH/CE). Also look for the SAE (Society of Au¬
tomotive Engineers) viscosity grade. Referring to
Table 1 , choose the viscosity grade appropriate for
the ambient temperatures expected during the peri¬
od of time until the next scheduled oil change.
Single-grade SAE 30 oil is preferable when temper¬
atures are consistently above freezing. Multigrade
oils are better when wide temperature variations are
expected.
IA caution I Do not use gasoline or gasoline ad¬
ditives containing methanol because methanol
can be corrosive to fuel system components.
Avoid using highly leaded gasolines and lead
additives because of the extra engine mainte¬
nance that will be required.
LPG Models
Use clean, fresh HD -5 grade liquified petroleum gas
(LPG) or equivalent product consisting of at least 90
TABLE 1. OIL VISCOSITY VS. TEMPERATURE
EXPECTED AMBIENT
TEMPERATURES
SAE
VISCOSITY
GRADE
32° F (0° C) and higher
30
10° F to 100° F (-12° C to 38° C)
15W-40
(OnaMax)
0° F to 80° F (-18° C to 27° C)
10W-30
10 W-40 |
-20° F to 50° F (-28° C to 10° C)
5W-30 1

STARTING BATTERIES
EXHAUST SYSTEM
The engine is equipped with a 12 volt electric starter.
Prompt starting requires sufficient battery capacity
and battery cable size. Neither cranking perfor¬
mance nor starter service life will be satisfactory
with an undersized battery.
Regular, monthly maintenance of batteries may be
required. See Periodic Maintenance and any
instructions available from the equipment or battery
manufacturer. It should be noted that as long as the
equipment is operated regularly, the automatic bat¬
tery recharging system on the engine should be
able to maintain battery charge. See OUT-OF-SER-
VICE PROTECTION under Operation regarding
battery care during storage for prolonged periods.
EXHAUST GAS IS DEADLY! Mobile engine-pow¬
ered equipment must never be operated inside
buildings or other enclosed spaces without ample
fresh air ventilation.
Stationary engine-powered equipment installed in¬
side buildings or other enclosed spaces must be
equipped with a leak-free exhaust system that car¬
ries all exhaust gases to the outside, well away from
all windows, doors, vents and other openings into
the building or enclosure.
It is the responsibility of the equipment operator(s)
to check for exhaust leaks on a daily basis and to
have all leaks repaired before continuing to operate
the equipment.

IAwARNiNGi EXHAUST GAS IS DEADLY!
Exhaust gases contain carbon monoxide, an odorless and colorless gas. Carbon monoxide is poi¬
sonous and can cause unconsciousness and death. Symptoms of carbon monoxide poisoning in¬
clude:
• Dizziness • Throbbing in Temples
• Nausea • Muscular Twitching
• Headache • Vomiting
• Weakness and Sleepiness • Inability to Think Coherently
IF YOU OR ANYONE ELSE EXPERIENCE ANY OF THESE S YMPTOMS, GET OUT INTO THE FRESH
AIR IMMEDIATELY. If symptoms persist, seek medical attention. Shut down the engine and do not
operate it until it has been inspected and repaired.
Make certain the exhaust system is properly installed. Inspect it every time the engine is started and
after every eight hours of continuous operation.
PRE-START CHECKS
Before the first start of the day and after every eight
hours of operation perform the maintenance
instructed in DAILY (8 HOUR) MAINTENANCE un¬
der Periodic Maintenance. Keep a log of mainte¬
nance and the hours run and perform any mainte¬
nance that may be due. Also, if the equipment has
been in storage, return the engine to service as
instructed under RETURNING THE ENGINE TO
SERVICE in this section.
Always follow the equipment manufacturer’s oper¬
ating instructions and observe all precautions when
operating power equipment.
IAwarningI Moving parts can cause severe
personal injury or death. Hot exhaust parts can
cause severe burns. Stay clear of hot or moving
parts. Make sure all protective shields and
guards are secure in place before starting up the
equipment.
STARTING
1 . C heck the oil levei if this is the first start of the
day and add oil as necessary.
IA caution] Starting the engine without oil
will cause severe engine damage. Always
keep the engine oil level between the Full
and Add marks on the dipstick.
2 . Fill the gasoline or LPG fuel tank, if necessary,
and open any fuel shutoff valve; for example,
the valve(s) at the LPG container(s).
3 . Release the clutch if the engine is so equipped.
4. If this is a gasoline engine with a manual choke,
pull the choke knob out to its full-choke position.
On equipment with a solenoid operated choke,
push the switch to its choke position. In warm
weather, however, or when the engine is warm,
try starting without the choke.
5 . Push the throttle knob or lever to the middle of
its speed range.
6 . Turn the ignition-start switch to its start position
and hold it there until the engine starts. Do not
crank for more than 30 seconds at a time and
wait at least one minute between tries when
cranking. See Troubleshooting if the engine
does not start after several tries.
7 . If this is a gasoline engine with a manual choke,
keep your hand on the choke knob and slowly
push it in to the full-open choke position, pulling
back if necessary to keep the engine running
smoothly. The colder the weather the longer it
will take the engine to start running smoothly
with the choke fully open. Do not operate the
equipment until the engine has warmed up suf¬
ficiently to run smoothly with the choke fully
open.

OPERATION IN HOT WEATHER
ENGINE BREAK-IN
Engine break-in as a result of proper care during the
first hours of operation of a new or rebuilt engine re¬
sults in the ideal fitting of all internal moving metal
parts, which is essentia! for top engine perfor¬
mance. For controlled engine break-in:
1. Operate the equipment as it is intended to be
operated. However, for the first 3 hours, if pos¬
sible, operate the equipment at about half the
available engine power, occasionally operating
at full engine power for brief periods. Also, if
possible, avoid prolonged low-speed, low-pow¬
er operation during engine break-in.
2. Proper engine oil is especially critical during
break-in because of the higher engine temper¬
atures that can be expected. See REC¬
OMMENDED ENGINE OIL in Introduction.
Change the oil if it is not appropriate for the am¬
bient temperatures during the break-in period.
See Table 1.
3. Check the oil level twice a day or after every 4
hours of operation during the first 24 hours of
operation.
4. Change the oil and oil filter after the first 24
hours of operation.
5. See Table 2 for engine models which require
valve clearance adjustment after the first 50
hours of operation.
OPERATION IN DUSTY CONDITIONS
1. Keep the engine cooling fins and flywheel air in¬
let screen clean.
2. Perform air cleaner maintenance more often
than normal—as required. See Table 2.
3. Change the engine oil and oil filter more often
than normal. See Table 2.
Pay particular attention to the following items when
operating the engine in temperatures above 100° F
(38° C):
1. Keep the flywheel air inlet screen and cylinder
cooling fins clean. See to it that nothing ob¬
structs air flow to and from the engine.
2. Check the oil level more frequently.
3. Change the oil and oil filter more often than nor¬
mal. See Table 2.
4. Make sure the engine oil viscosity is appropri¬
ate for the ambient temperatures and change
the oii if necessary. See Table 1.
OPERATION IN COLD WEATHER
Pay particular attention to the following items when
operating the engine in temperatures below freez¬
ing:
1. M ake sure the engine oil viscosity is appropri¬
ate for the ambient temperatures and change
the oil if necessary. See Table 1. If the tempera¬
ture drops before you have the chance to
change the oil, warm up the engine by moving
the equipment into a heated space before at¬
tempting to start the engine or change oil.
I Awarning I EXHAUST GAS IS DEADLY!
Never operate mobile engine-powered
equipment indoors without ample fresh air
ventilation.
2. Use fresh gasoline and fill the fuel tank after
each day’s use to reduce problems with mois¬
ture condensation if this is a gasoline engine.
3. Keep the battery in a well-charged condition.
4. A fter each use push the equipment throttle
knob or lever to the middle of its speed range
so that if ice forms on the linkage during storage
it will be easier to start the engine.
7

OUT-OF-SERVICE PROTECTION
Protect an engine that will be out of service for more
than 30 days as follows:
5. Clean the governor linkage and wrap it with a
clean doth for protection.
6. Plug the exhaust outlet to prevent moisture,
dirt, bugs, etc. from entering.
7. Provide a suitable cover for the entire unit.
1. R un the engine until it reaches norma! operat¬
ing temperature, shut off the fuel supply and let
the engine run until it stops. Also, if the equip¬
ment will not be operated for more than 120
days, add a fuel preservative (OnaFresh ™ ) to
the equipment fuel tank (gasoiine engines
only). Follow the instructions on the container
label. Unless a preservative (stabilizer) is add¬
ed, the gasoiine will deteriorate causing fuel
system corrosion, gum formation and varnish¬
like deposits which can lead to hard starting
and rough operation.
[Awarning] Gasoline preservatives (stabi¬
lizers) are toxic. Follow the instructions on
the container label. Avoid skin contact.
Wash your hands with soap and water after
dispensing the fluid.
2. Drain the oil from the engine while it is still
warm. Refill with fresh oil and attach a tag stat¬
ing the viscosity of the oil used.
3. Remove the spark plugs and squirt 1 ounce
(2 tablespoons or 28 grams) of rust inhibitor or
SAE 30 oil into each cylinder. Crank the engine
over a few times and reinstall the spark plugs.
4. Perform air cleaner maintenance as instructed
in Periodic Maintenance.
. If so equipped, disconnect the battery (nega¬
tive [-] cable first) and follow the battery or
equipment manufacturer’s storage instruc¬
tions.
1. Remove the cover and all protective wrapping
and the plug from the exhaust outlet.
2. Check the tag on the oil base. Change the oil if
the viscosity is not appropriate for the expected
ambient temperatures. See Table 1.
;heck the fuel filter and fuel Sines to make sure
^ \ §
Check to see that the choke, throttle and gover¬
nor linkages move freely.
5. If so equipped, clean and check the batten/ ac¬
cording to the battery or equipment manufac¬
turer's instructions and connect the battery
cables (positive [+] cable first).
6 . Start the engine. T he initial startup may be slow
and there may be smoke and rough operation
for a few minutes until the oil in the cylinder
burns off. If the engine does not start, clean or
replace the spark plugs as they may have been
fouled by the oil added to the cylinder when the
equipment was stored.
OnaFresh is a trademark of the Onan Corporation.